Insertion force quality consistency investigation of electrical connector

Reliable and stable insertion force is usually of utmost significant characteristic in a system which contains thousands of electrical connectors. Even if an electrical connector fails, it will lead to the whole system collapses. This paper established an insertion force model of a kind of electrical connector based on simply supported beam mechanical calculation theory. Experiment and simulation were used to verify the correctness of the insertion force model. The quality characteristic distribution of insertion force was obtained via assembling a certain amount of electrical connectors based on the Monte Carlo stochastic modeling method mathematics thought. The relationships between three design parameters (pin diameter, wire spring diameter, the angle between the wire spring and inner sleeve) and insertion force of electrical connector were investigated in the present study by using Abaqus software. The quality consistency of insertion force was optimized on the basis of the Robust Design Principle by key parameters design.